C5 Clutch Pack Components

ALLISON 1000 & 2000 PRODUCT FAMILIES C5 CLUTCH PACK COMPONENTS

B. C5

Piston

C. C5

Backplate D. C5 Return

Spring

Assembly

A. C5 Clutch

Pack

A. Inspect friction plate contact faces for excessive wear, embedded metal particles, cracking and distortion. Inspect the plate splines for burrs, cracks and damaged spline teeth. Replace the plate if spline damage cannot be repaired using a soft stone or crocus cloth. Minimum allowable friction plate thickness is 2.375mm (0.0935 inch). Minimum allowable oil groove depth is 0.20mm (0.008 inch). Maximum allowable coning is 0.225mm (0.009 inch). NOTE: Battered and worn spline teeth may be an indicator of driveline issues. Replace the clutch plates and check the driveline. NOTE: Anti-freeze (glycol) and/or water will adversely affect the bonding agent between the friction material and steel core. Replace any friction plates which have been exposed to water and/or glycol. Friction material which is loose or flaking indicates that the plates have been exposed to glycol and/or water. Reference SIL 18-TR-98, Rev. A for details.

Inspect reaction plate contact surfaces for chips, cracks, grooves, scoring and signs of overheating. Inspect reaction plate tangs for chips, cracks and signs of battering. Replace the plate if damage cannot be repaired using a soft stone or crocus cloth. Replace the plate if any tangs are broken, bent or otherwise distorted. Maximum allowable coning is 0.295mm (0.0116 inch). Minimum allowable plate thickness is indicated in the chart below.

Part Minimum ID Number Thickness Number

29536481 1.935 mm 1 (0.0762 inch)

29536482 2.435 mm 2 (0.0959 inch)

29536483 2.935 mm 3 (0.1156 inch)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) C5 CLUTCH PACK COMPONENTS

Inspect the piston internal and external sealring grooves.

Supersession Information

C5 Friction Plate Update Reference SIL 31-1K2K-01

2WD C5 Piston (100%)

B. Inspect the C5 clutch piston for burrs, chips and cracks. Inspect the internal and external sealring grooves for burrs, chips and cracks. Replace the piston if damage cannot be repaired using a soft stone or crocus cloth. C. Inspect the C5 clutch backplate. Replace the backplate if it has burrs, scoring or other damage which cannot be repaired using a soft stone or crocus cloth. Replace the backplate if it is cracked or broken. Check the backplate for coning. Replace the backplate if any coning is detected. Minimum allowable backplate thickness is 17.90mm (0.7047 inch). D. Inspect the C5 clutch return spring plate for cracks, chips, burrs, bends and distortion. Replace the plate if damage cannot be repaired using a soft stone or crocus cloth. Replacethe assembly springs if broken, cracked, permanently set, showing signs of wear due to rubbing or showing signs of discoloration. Reference the Service Manual Spring Data Charts for spring specifications and identification.

4WD C5 Piston (70%)

C. Clutch Plate

Thickness and

Coning Coned Plate

Flat Plate Check Using Feeler Gauge Current Friction Plates Have Sunburst Pattern.